INSTALLATION INSTRUCTIONS HD BUMPER AND WINCH MOUNTING KIT Part Number: 74777, Application: 08-NEWER FORD SUPER DUTY WARNING

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1 INSTALLATION INSTRUCTIONS HD BUMPER AND WINCH MOUNTING KIT Part Number: 74777, Application: 08-NEWER FORD SUPER DUTY Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided installation and operating instructions and other information on labels and in this guide. This information alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you must use your own good judgment. CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT. This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or death. WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean: WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations. CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow recommendations. This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general information worthy of special attention. WARNING INJURY HAZARD Failure to observe these instructions could lead to severe injury or death. Always use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged when / if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, fire or personal injury. Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury. Always use extreme caution when cutting and trimming during fitting. Always remove jewelry and wear eye protection. Never lean over battery while making connections. Never route electrical cables: Across any sharp edges. Through or near moving parts. Near parts that become hot. Always insulate and protect all exposed wiring and electrical terminals. Always install terminal boots as directed in installation instructions. Always use appropriate and adequate care in lifting components into place. Always insure components will remain secure during installation and operation. Always tighten all nuts and bolts securely, per the installation and operation instructions. Always perform regular inspections and maintenance on the winch, winch mount and related hardware. WARN INDUSTRIES PAGE A0

2 Caution Moving Parts Entanglement Hazard Failure to observe these instructions could lead to minor or moderate injury. Always take time to fully read and understand the installation and Operations Guide included with this product. Never operate this product if you are under 16 years of age. Never operate this product when under the influence of drugs, alcohol or medications. Read installation and operating instructions thoroughly. Notice Equipment Damage Always refer to the Installation and Specification Guide, supplied in the winch kit, for all wiring schematics and specific details on how to wire this WARN product to your vehicle. Read installation and operating instructions thoroughly. I. BEFORE YOU BEGIN READ INSTALLATION INSTRUCTION THOROUGHLY. II. TABLE OF CONTENTS Parts List page 2 Tools Required page 3 Torque Specifications page 3 Installation page 3-14 Maintenance/Care page 15 III. PARTS LIST Part Number Qty Description OR BUMPER, FRONT, WITH TUBES OR WITHOUT TUBES HARDWARE KIT LOWER MOUNTING BRACKET, LH LOWER MOUNTING BRACKET, RH SHIM OE FOG LIGHT BRACKET OE FOG LIGHT BRACKET SPACER FRAME BRACKET, LH FRAME BRACKET, RH TI CONTROL BOX BRACKET BATTERY BOLT REPLACEMENT KIT LIGHT KIT WARN INDUSTRIES PAGE A0

3 IV. TOOLS REQUIRED V. TORQUE SPECIFICATIONS -METRIC SOCKET SET ¼ 8 lb. ft. (10.8 N-m) -STANDARD SOCKET SET 5/16 17 lb. ft. (12.5 N-m) -3/8 DRIVE RATCHET 3/8 30 lb. ft. (40.7 N-m) -1/2 DRIVE RATCHET 7/16 50lb. ft. (67.8 N-m) -STANDARD WRENCH SET ½ 75 lb. ft. (101.7 N-m) -TAPE MEASURE 5/8 90 LB. FT. (122 N-m) -TORQUE WRENCH EXPLODED VIEW OF BUMPER AND BRACKETS WARN INDUSTRIES PAGE A0

4 VI. INSTALLATION 1. Remove the factory front bumper. First remove the outer bumper support braces from the vehicle frame. Then remove the front mounting bolts accessed through the air slots in the bumper. Disconnect the wiring to the factory fog lamps and hood release bracket if the vehicle is equipped with them. Discard bumper and outer support brackets. See Figure 1. Remove the factory tow hooks and discard. DRILL OUT FORWARD INSIDE HOLE TO ½. Figure 1: Passenger s Side Shown. Removal of factory bumper. Drilling hole out to ½. Once the factory bumper and brackets are removed, drill out the forward inside hole on the top of the frame to ½. Repeat this for both sides of the vehicle. WARNING Drilling operations can cause flying chips. WEAR SAFETY GOGGLES. Flying chips can cause eye injury. WARN INDUSTRIES PAGE A0

5 2. Install the outer frame bracket to both sides of the vehicle. See Figure 2 and 3. Use the supplied 5/8 hardware. Insert a 5/8 bolt, lock washer and flat washer through the outer frame bracket and into the appropriate frame hole. Install a 5/8 flat washer and 5/8 nut with a steel anti-rotation stick welded to it onto each bolt, 2 on each bracket. Install a ½ x 1-1/2 long bolt and flat washer through the forward frame bracket hole and through the frame. Install a ½ flat washer, lock washer and nut onto the bolt. Do not tighten these bolts at this time. 5/8 FLAT WASHER AND 5/8 NUT WITH STICK ½ X 1-1/2 BOLT, FLAT WASHER, LOCK WASHER AND NUT. Figure 2: Installation of outer frame bracket and 5/8 nut with a steel anti-rotation stick. WARN INDUSTRIES PAGE A0

6 5/8 BOLT, LOCK WASHER AND FLAT WASHER ½ X 1-1/2 BOLT AND FLAT WASHER Figure 3: 5/8 and ½ hardware for lower frame bracket. 3. Install the main frame brackets to the vehicle frame. See Figure 4 for appropriate left and right bracket locations. First install the main frame brackets using the ½ x 2 long bolts through the factory tow hook mounting holes inside the frame. Install the frame bracket onto the frame where the tow hooks used to mount. Take a ½ x 2 long bolt and flat washer and insert it through the frame bracket and frame. Install a ½ flat washer, lock washer and nut onto the bolt from the bottom. Repeat this for all three bottom frame holes on each frame bracket. The outermost bolt will not allow a standard flat washer to be installed onto the bolt. Install the forward outer bolt using the smaller ½ flat washer. Do not tighten at this time. See Figure 5. Once all the bolts are installed on each side, begin tightening the bolts making sure the brackets are inline with the vehicle. Use a tape measure to make sure the main frame brackets are square to each other. Use Figure 4 to help with this step. Measure across the top front of the frame brackets and then measure across the top back of the main frame bracket to make sure they are square. It may be necessary to loosen the bolts slightly to allow for the brackets to move. Both measurements should be equal. WARN INDUSTRIES PAGE A0

7 Once the brackets are positioned tighten the ½ hardware. Do not tighten the lower brackets. MEASURE ACROSS THE FRONT AND BACK OF THE FRAME BRACKETS TO ENSURE THEY ARE PARALLEL. BE SURE BRACKET IS POINTING STRAIGHT AHEAD. Figure 4: Passenger s Side Main frame brackets and bolt locations. 4. Once the main frame brackets are square to each other, torque all six of the mounting bolts using the supplied torque specification in the beginning of this instruction manual. 5. If you are installing a winch with this bumper installation, do so now. If you are installing a Warn 16.5ti winch, you must first install the supplied control pack relocation bracket to the winch and solenoid box before installing the winch. See Figure 5. Use the supplied hardware to mount the control pack. If you are installing a Warn M15 or M12, use the bracket or clamps supplied with the winch to mount the control pack. See Figure 6. Be sure to install the winch ground strap before installing winch. WARN INDUSTRIES PAGE A0

8 Figure 5: 16.5ti Control Pack. Figure 6: M15 Control Pack 6. Once the control pack is installed on the winch, insert the winch into the bumper. The control pack should be facing up and the front of the winch should have the four mounting holes. Insert the winch by first tipping the end with the clutch lever up and inserting the control pack end in the bumper first. Then insert the clutch lever end in the bumper. Use the hardware supplied with the winch to properly mount the winch to the bumper. Following the instructions supplied with the winch for the proper bolt location. The winch comes with two different length 7/16 bolts, so read the instructions with the winch to ensure the proper locations. WARN INDUSTRIES PAGE A0

9 7. Due to the tolerances in the vehicle frame, mounting brackets and the bumper it will be necessary to attach shims to the inside of the bumper to ensure a good fit to the bumper. The bumper was designed to have two shims attached to the inside surface of the mounting surface on each side of the bumper. This allows the bumper to be moved side to side for a proper fit to the vehicle body. The first step is to measure the width across the frame brackets from outside of frame bracket to outside of the other frame bracket. This same measurement was done in step 4. After measuring the outside width across the frame brackets, measure the inside width of the bumper. The frame brackets fit inside the center cavity of the bumper, thus this measurement should be smaller. Determine the difference between the two dimensions. Each shim is an 1/8 thick. Determine the number of shims required to make up the difference in the measurements. For example, if there is a 3/8 difference, then 3 shims will be required. Install one shim to the inside of one side of the bumper and the remaining two shims to the inside of the opposite side of the bumper. Use the ¼ bolts and nuts to secure the shim to the frame bracket. See Figure 7. INSTALL SHIM (S) TO THE INSIDE OF BUMPER USING ¼ HARDWARE Figure 7: Attaching shim(s) to inside of bumper. WARN INDUSTRIES PAGE A0

10 8. Once the proper amount of shims has been attached to the inside of the bumper, the bumper can be installed. The easiest and most careful way to install the bumper without damaging the bumper and /or vehicle is to use a floor jack under the bumper and someone to help guide the bumper into place. Place something of the floor jack to keep it from scratching the bumper. Gently set the bumper on the floor jack and center it so it is balanced. Slowly jack the bumper up and guide it into the vehicle. Watch the frame brackets to make sure you are lined up. As the bumper gets close to being in position, make sure that the headlight tubes to do not touch the vehicle fenders. Once the bumper is positioned to the outside of the main frame brackets on both sides of the vehicle, look at the clearance between the head light tubes and the fenders. If there is more gap on one side, it may be necessary to move a shim from one side of the bumper to the opposite side to move the bumper away from the fender. See Figure 8. Caution Falling Parts Hazard Failure to observe these instructions could lead to minor or moderate injury. Always take time to make sure that the bumper is centered on the jack. Always get help when lifting heavy objects. Read installation and operating instructions thoroughly. The Warn HD Bumper was designed to fit close to the body to achieve a clean looking fit of the bumper. If there is more gap on one side, remove a shim from the side of the frame bracket and add it to the opposite side. ADJUST THE SHIM PLACEMENT TO GET AN EQUAL GAP BETWEEN THE HEAD LIGHT TUBE AND THE FENDER ON BOTH SIDES OF THE VEHICLE. Figure 8: Shim adjustment and bumper to body clearance. WARN INDUSTRIES PAGE A0

11 9. Once the bumper is positioned side to side through shim adjustment, line up the holes in the bumper to the holes in the frame brackets. Upon lining the holes up, insert a ½ Carriage bolt (round head, square neck) through the frame bracket and the bumper. The bolts MUST be installed through the frame bracket first for proper fit of the square neck on the bolts into the square holes in the frame brackets. See Figure 9. INSERT CARRIAGE BOLTS THROUGH FRAME BRACKET. THE THREADED END OF THE BOLTS POINTING OUTWARD. Figure 9: Carriage bolt placement. 10. Once the four bolts are installed on each side of the bumper, attach a ½ flat washer and ½ lock nut onto each of the eight bolts. 11. Attach the lower mounting brackets to the bumper holes. See Figure 10. Once the brackets are positioned properly, insert a ½ carriage bolt through the inside of the bumper and out through the mounting bracket in each the two locations on both sides of the vehicle. Install a ½ flat washer, lock washer and nut onto each bolt. WARN INDUSTRIES PAGE A0

12 Figure 10: Lower mounting bracket installation to bumper. 12. Now the bumper can be positioned up and down to properly fit the bumper to the bottom of the headlights and the grille. Jack up the bumper until the desired height is found. Once this position is found, evenly tighten all eight bolts. Torque the ½ bolts to the torque specification in the beginning of this manual. 13. If you are installing a bumper with grille guard, install the supplied driving lights to the brackets in the bumper light ports. Following the instructions supplied with the lights for the proper torque and wiring. See Figure 11. If your bumper does not have a grille guard, install the fog light hole blocker plates. WARN INDUSTRIES PAGE A0 Figure 11: Light Mounted to Bumper.

13 14. Install the front license plate to the front of the bumper under the winch fairlead opening. Two holes are provided for attaching the license plate. Use the supplied ¼ bolts, flat washers and lock nuts and torque to the stated specification at the beginning of this manual. 15. If your vehicles hood release was attached to the factory bumper, install the hood release bracket shown in the exploded view at the beginning of this manual. Use the 3/8 hardware provided. 16. Refer to the winch manual for proper routing of the winch cables. WARNING READ THE VEHICLE S OPERATOR MANUAL, WINCH OPERATOR MANUAL, AND ALL WARNING LABELS PRIOR TO OPERATION OF WINCH. THE BUMPER AND WINCH MOUNTING INSTALLATION IS NOW COMPLETE. PROCEED TO SECTION IV TITLED MAINTENANCE/CARE. WARNING FAILURE TO SECURELY TIGHTEN ALL BOLTS ON THE WINCH PLATE, WINCH, AND FAIRLEAD CAN RESULT IN PRODUCT FAILURE, WHICH MAY RESULT IN VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH. DOUBLE CHECK THAT ALL BOLTS ARE SECURELY TIGHTENED PRIOR TO USE. VII. MAINTENANCE/CARE 1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware that appears rusted or deformed. 2. Inspect all nuts and bolts on the winch, winch mount, and related hardware prior to each use. Tighten all nuts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced. 3. Check all cables prior to use. Replace cables that look worn or frayed. 4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely. WARNING PERFORM REGULAR INSPECTIONS ON THE WINCH, WINCH MOUNT, AND RELATED HARDWARE. NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS. FAILURE TO FOLLOW THIS WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH. WARN INDUSTRIES PAGE A0

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